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Models - Sme.aluminum Extrusion Fsi PDF
Models - Sme.aluminum Extrusion Fsi PDF
This model is licensed under the COMSOL Software License Agreement 5.3.
All trademarks are the property of their respective owners. See www.comsol.com/trademarks.
Introduction
Out of all metals, the most frequently extruded is aluminum. Aluminum extrusion entails
using a hydraulic ram to squeeze an aluminum bar through a die. This process will form
the metal into a particular shape. Extruded aluminum is used in many manufacturing
applications, such as building components for example. In massive forming processes like
rolling or extrusion, metal alloys are deformed in a hot solid state with material flowing
under ideally plastic conditions. Such processes can be simulated effectively using
computational fluid dynamics, where the material is considered as a fluid with a very high
viscosity that depends on velocity and temperature. Internal friction of the moving
material acts as a heat source, so that the heat transfer equations are fully coupled with
those ruling the fluid dynamics part. This approach is especially advantageous when large
deformations are involved.
This model is adapted from a benchmark study in Ref. 1. The original benchmark solves a
thermal-structural coupling, because it is common practice in the simulation of such
processes to use specific finite element codes that have the capability to couple the
structural equations with heat transfer. The alternative scheme discussed here couples non-
Newtonian flow with heat transfer equations. In addition, because it is useful to know the
stress in the die due to fluid pressure and thermal loads, the model adds a structural
mechanics analysis.
The die design is courtesy of Compes S.p.A., while the die geometry, boundary
conditions, and experimental data are taken from Ref. 1.
Note: This application requires the Heat Transfer Module and the Structural Mechanics
Module. In addition, it uses the Material Library.
Model Definition
The model considers steady-state conditions, assuming a billet of infinite length flowing
through the die. In the actual process, the billet is pushed by the ram through the die and
its volume is continuously reducing.
Figure 1 shows the original complete geometry with four different profiles. To have a
model with reasonable dimensions, consider only a quarter of the original geometry. The
simplification involved in neglecting the differences between the four profiles does not
MATERIAL PROPERTIES
The documentation for the benchmark model (Ref. 1) serves as the data source for
properties of the two main materials: AISI steel for the die and the container (the ram is
not considered here) and aluminum for the billet.
Non-Newtonian Flow
The properties of the aluminum were experimentally determined and then checked using
literature data for the same alloy and surface state. However the benchmark proposes an
experimental constitutive law, suited for the structural mechanics codes usually used to
simulate such processes, in the form of the flow stress data. For this model this requires a
recalculation of the constitutive law to derive a general expression for the viscosity. The
equivalent von Mises stress, σeqv, can be defined in terms of the total contraction of the
deviatoric stress tensor as
3
σ eqv = --- τ:τ
2
· ·
or, using τ = 2ηε where ε is the strain rate and η is the viscosity, as
2· ·
σ eqv = 6η ε :ε (1)
· 2· ·
φ eqv ≡ --- ε :ε
3
T
· ∇u + ( ∇u ) 1·
ε = ------------------------------- = --- γ
2 2
·
The shear rate γ is defined as
· 1
γ = γ· = --- γ· :γ·
2
so that
1 ·
φ eqv = ------- γ
3
σ eqv = κ f
states that plastic yielding occurs if the equivalent stress, σeqv, reaches the flow stress, κf.
The viscosity is defined as (see Ref. 2 for further details)
κf
η = -------------
· -
3φ eqv
The organizers of the benchmark propose specific flow-stress data expressed in terms of a
generalized Zener-Hollomon function
1
---
Z n
asinh ----
A
η = ----------------------------------
·
3αγ
--------
Q -
1 · RT
Z = ------- γ e
3
Structural Analysis
Because the model geometry is a quarter of the actual geometry, use symmetric boundary
conditions for the two orthogonal planes. On the external surfaces of the die, apply roller
boundary conditions because in reality other dies, not considered here, are present to
increase the system’s stiffness.
The main loads are the thermal loads from the heat transfer analysis and pressures from the
fluid dynamics analysis.
The external temperature of the ram and the die is held constant at 450 °C (723 K). The
ambient temperature is 25 °C (298 K). For the heat exchange between aluminum and
steel, use the heat transfer coefficient of 11 N/(s·mm·K). Also consider convective heat
exchange with air outside the profiles with a fixed convective heat transfer coefficient of
15 W/(m2·K).
PART VALUE
Non-Newtonian Flow
At the inlet, the ram moves with a constant velocity of 0.5 mm/s. Impose this boundary
condition by simply applying a constant inlet velocity. At the outlet, a normal stress
condition with zero external pressure applies. On the surfaces placed on the two symmetry
planes, use symmetric conditions. Finally, apply slip boundary conditions on the
boundaries placed outside the profile.
2. E.D. Schmitter, “Modelling massive forming processes with thermally coupled fluid
dynamics,” Proceedings of the COMSOL Multiphysics User's Conference 2005
Frankfurt, Frankfurt, Germany.
Modeling Instructions
From the File menu, choose New.
NEW
In the New window, click Model Wizard.
MODEL WIZARD
1 In the Model Wizard window, click 3D.
2 In the Select Physics tree, select Heat Transfer>Conjugate Heat Transfer>Laminar Flow.
3 Click Add.
4 In the Select Physics tree, select Structural Mechanics>Solid Mechanics (solid).
5 Click Add.
6 Click Study.
7 In the Select Study tree, select Preset Studies for Selected Physics Interfaces>Stationary.
8 Click Done.
GEOMETRY 1
Import 1 (imp1)
1 On the Home toolbar, click Import.
2 In the Settings window for Import, locate the Import section.
3 Click Browse.
5 Click Import.
6 Click the Zoom Extents button on the Graphics toolbar.
You should now see the following geometry.
GLOBAL DEFINITIONS
Parameters
1 On the Home toolbar, click Parameters.
2 In the Settings window for Parameters, locate the Parameters section.
3 In the table, enter the following settings:
DEFINITIONS
Variables 1
1 On the Home toolbar, click Variables and choose Local Variables.
2 In the Settings window for Variables, locate the Variables section.
3 In the table, enter the following settings:
Explicit 1
1 On the Definitions toolbar, click Explicit.
2 In the Settings window for Explicit, type Outside in the Label text field.
3 Locate the Input Entities section. From the Geometric entity level list, choose Boundary.
4 Select Boundaries 35–38, 42, 43, 48, 49, 51, 53, 68, 69, 76–79, 84, 85, 91, 93, 100,
101, 103, and 105 only.
For more convenience in selecting these boundaries, you can click the Paste Selection
button and paste the above numbers.
Explicit 2
1 On the Definitions toolbar, click Explicit.
2 In the Settings window for Explicit, type Interior in the Label text field.
3 Locate the Input Entities section. From the Geometric entity level list, choose Boundary.
4 Select Boundaries 8, 11, 14, 15, 19, 20, 24, 29–34, 41, 47, 50, 56–58, 62, 67, 70, 71,
74, 75, 83, 86–90, 99, 102, 106, and 107 only.
Before creating the materials for the model, specify the fluid and solid domains. Using this
information, the software can detect which material properties are needed.
H E A T TR A N S F E R ( H T )
Fluid 1
1 In the Model Builder window, under Component 1 (comp1)>Heat Transfer (ht) click
Fluid 1.
2 Select Domains 3 and 4 only.
3 In the Settings window for Fluid, locate the Domain Selection section.
4 Click Create Selection.
5 In the Create Selection dialog box, type Billet in the Selection name text field.
6 Click OK.
1 In the Model Builder window, under Component 1 (comp1) click Laminar Flow (spf).
2 In the Settings window for Laminar Flow, locate the Physical Model section.
3 From the Compressibility list, choose Incompressible flow.
1 In the Model Builder window, under Component 1 (comp1) click Solid Mechanics (solid).
2 In the Settings window for Solid Mechanics, locate the Domain Selection section.
3 Click Clear Selection.
4 Select Domains 1 and 2 only.
ADD MATERIAL
1 On the Home toolbar, click Add Material to open the Add Material window.
2 Go to the Add Material window.
3 In the tree, select Material Library>Tool Steels>H11 mod (AISI 610)>
H11 mod (AISI 610) [solid]>H11 mod (AISI 610) [solid,triple tempered].
4 Click Add to Component in the window toolbar.
MATERIALS
Because the heat capacity only enters the transient heat transfer equation, this setting
does not affect the steady-state simulation described here; it is provided for
completeness in case you want to extend the model to perform transient simulations.
Material 2 (mat2)
1 In the Model Builder window, under Component 1 (comp1) right-click Materials and
choose Blank Material.
5 On the Home toolbar, click Add Material to close the Add Material window.
With the materials defined, you can set up the remaining physics of the model.
1 In the Model Builder window’s toolbar, click the Show button and select
Advanced Physics Options in the menu.
2 In the Model Builder window, under Component 1 (comp1) click Laminar Flow (spf).
3 In the Settings window for Laminar Flow, click to expand the Advanced settings section.
4 Locate the Advanced Settings section. Find the Pseudo time stepping subsection. Clear
the Use pseudo time stepping for stationary equation form check box.
Initial Values 1
1 In the Model Builder window, under Component 1 (comp1)>Laminar Flow (spf) click
Initial Values 1.
2 In the Settings window for Initial Values, locate the Initial Values section.
3 In the p text field, type P_init.
4 In the Model Builder window, click Laminar Flow (spf).
Symmetry 1
1 On the Physics toolbar, click Boundaries and choose Symmetry.
2 Select Boundaries 9 and 112 only.
0 x
0 y
V_ram z
Outlet 1
1 On the Physics toolbar, click Boundaries and choose Outlet.
2 Select Boundary 40 only.
3 In the Settings window for Outlet, locate the Pressure Conditions section.
4 In the p0 text field, type P_init.
H E A T TR A N S F E R ( H T )
Initial Values 1
1 In the Model Builder window, under Component 1 (comp1)>Heat Transfer (ht) click
Initial Values 1.
2 In the Settings window for Initial Values, type T_container in the T text field.
3 In the Model Builder window, click Heat Transfer (ht).
Temperature 1
1 On the Physics toolbar, click Boundaries and choose Temperature.
2 Select Boundaries 2, 5, and 7 only.
3 In the Settings window for Temperature, locate the Temperature section.
4 In the T0 text field, type T_container.
Heat Flux 2
1 On the Physics toolbar, click Boundaries and choose Heat Flux.
2 In the Settings window for Heat Flux, locate the Boundary Selection section.
3 From the Selection list, choose Outside.
4 Locate the Heat Flux section. Click the Convective heat flux button.
5 In the h text field, type H_conv.
6 In the Text text field, type T_air.
Outflow 1
1 On the Physics toolbar, click Boundaries and choose Outflow.
2 Select Boundary 40 only.
Thin Layer 1
1 On the Physics toolbar, click Boundaries and choose Thin Layer.
2 In the Settings window for Thin Layer, locate the Boundary Selection section.
3 From the Selection list, choose Interior.
4 Locate the Thin Layer section. From the Specify list, choose Thermal resistance.
5 In the Rs text field, type 1/Heat_alfe.
Also set the layer density and heat capacity for completeness. These properties are
required only in a time-dependent study step. Use the material already defined for the
solid domain.
MATERIALS
H E A T TR A N S F E R ( H T )
Thin Layer 1
1 In the Model Builder window, under Component 1 (comp1)>Heat Transfer (ht) click
Thin Layer 1.
2 In the Settings window for Thin Layer, locate the Thermodynamics section.
3 From the ρs list, choose From material.
4 From the Cp, s list, choose From material.
1 In the Model Builder window, under Component 1 (comp1) click Solid Mechanics (solid).
2 Select Domains 1 and 2 only.
For faster convergence use linear elements. You can always refine the solution using the
default quadratic elements.
3 In the Model Builder window’s toolbar, click the Show button and select Discretization in
the menu.
4 In the Settings window for Solid Mechanics, click to expand the Discretization section.
5 From the Displacement field list, choose Linear.
Roller 1
1 On the Physics toolbar, click Boundaries and choose Roller.
2 Select Boundaries 2, 5, and 7 only.
Symmetry 1
1 On the Physics toolbar, click Boundaries and choose Symmetry.
2 Select Boundaries 1, 4, 110, and 111 only.
Boundary Load 1
1 On the Physics toolbar, click Boundaries and choose Boundary Load.
0 t1
0 t2
-p n
MULTIPHYSICS
1 In the Model Builder window, under Component 1 (comp1)>Multiphysics click
Nonisothermal Flow 1 (nitf1).
2 In the Settings window for Nonisothermal Flow, locate the Flow Heating section.
3 Select the Include viscous dissipation check box.
MESH 1
On the Mesh toolbar, click Boundary and choose Free Triangular.
Free Triangular 1
1 Click the Zoom Box button on the Graphics toolbar.
Size 1
1 Right-click Component 1 (comp1)>Mesh 1>Free Triangular 1 and choose Size.
2 In the Settings window for Size, locate the Element Size section.
3 Click the Custom button.
4 Locate the Element Size Parameters section. Select the Maximum element size check box.
5 In the associated text field, type 0.0014.
6 Select the Curvature factor check box.
7 In the associated text field, type 0.2.
8 Click Build Selected.
9 On the Mesh toolbar, click Swept.
Swept 1
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 click Swept 1.
2 In the Settings window for Swept, locate the Domain Selection section.
3 From the Geometric entity level list, choose Domain.
4 Select Domain 4 only.
5 On the Mesh toolbar, click Distribution.
Distribution 1
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1>Swept 1 click
Distribution 1.
2 In the Settings window for Distribution, locate the Distribution section.
3 In the Number of elements text field, type 24.
4 Click Build All.
5 On the Mesh toolbar, click Free Tetrahedral.
Size 1
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 right-click
Free Tetrahedral 1 and choose Size.
2 In the Settings window for Size, locate the Element Size section.
3 Click the Custom button.
4 Locate the Element Size Parameters section. Select the Maximum element size check box.
Size 2
1 Right-click Free Tetrahedral 1 and choose Size.
2 In the Settings window for Size, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Boundary.
4 Select Boundaries 12 and 13 only.
5 Locate the Element Size section. Click the Custom button.
6 Locate the Element Size Parameters section. Select the Maximum element size check box.
7 In the associated text field, type 0.002.
Size 3
1 Right-click Free Tetrahedral 1 and choose Size.
2 In the Settings window for Size, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Boundary.
4 Select Boundaries 24, 31, 32, 70, 88, and 106 only.
5 Locate the Element Size section. Click the Custom button.
6 Locate the Element Size Parameters section. Select the Minimum element size check box.
7 In the associated text field, type 1e-5.
Size
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 click Size.
2 In the Settings window for Size, locate the Element Size section.
3 From the Predefined list, choose Finer.
STUDY 1
Step 1: Stationary
Use two stationary study steps. Solve first for the fluid dynamics and heat transfer to
determine the thermal load and the pressure load and then for the structural mechanics.
1 In the Model Builder window, expand the Study 1 node, then click Step 1: Stationary.
2 In the Settings window for Stationary, locate the Physics and Variables Selection section.
3 In the table, clear the Solve for check box for the Solid Mechanics interface.
Step 2: Stationary 2
1 On the Study toolbar, click Study Steps and choose Stationary>Stationary.
2 In the Settings window for Stationary, locate the Physics and Variables Selection section.
3 Select the Modify physics tree and variables for study step check box.
4 In the Physics and variables selection tree, select Component 1 (comp1)>
Laminar Flow (spf).
5 Click Disable in Solvers.
Solution 1 (sol1)
1 On the Study toolbar, click Show Default Solver.
2 In the Model Builder window, expand the Study 1>Solver Configurations node.
3 In the Model Builder window, expand the Solution 1 (sol1) node.
4 In the Model Builder window, expand the Study 1>Solver Configurations>
Solution 1 (sol1)>Stationary Solver 2 node.
5 Right-click Study 1>Solver Configurations>Solution 1 (sol1)>Stationary Solver 2 and
choose Iterative.
6 On the Study toolbar, click Compute.
RESULTS
Temperature (ht)
The first default plot shows the temperature (Figure 3).
Data Sets
Modify the third default plot to see the velocity field and streamlines at the profile section
(Figure 4).
Velocity (spf)
1 In the Model Builder window, under Results click Velocity (spf).
2 In the Settings window for 3D Plot Group, locate the Data section.
3 From the Data set list, choose Study 1/Solution Store 1 (sol2).
Slice
1 In the Model Builder window, expand the Velocity (spf) node, then click Slice.
2 In the Settings window for Slice, locate the Plane Data section.
3 From the Plane list, choose XY-planes.
4 From the Entry method list, choose Coordinates.
5 In the Z-coordinates text field, type 0.0151.
6 On the Velocity (spf) toolbar, click Plot.
Streamline 1
1 In the Model Builder window, under Results right-click Velocity (spf) and choose
Streamline.
2 In the Settings window for Streamline, click Replace Expression in the upper-right corner
of the Expression section. From the menu, choose Component 1>Laminar Flow>
Velocity and pressure>u,v,w - Velocity field (spatial frame).
3 Locate the Streamline Positioning section. From the Positioning list, choose
Start point controlled.
4 Locate the Coloring and Style section. From the Line type list, choose Tube.
5 Click to expand the Inherit style section. Locate the Inherit Style section. From the Plot
list, choose Slice.
Color Expression 1
1 Right-click Results>Velocity (spf)>Streamline 1 and choose Color Expression.
2 In the Settings window for Color Expression, click Replace Expression in the upper-right
corner of the Expression section. From the menu, choose Component 1>Laminar Flow>
Velocity and pressure>spf.U - Velocity magnitude.
Streamline 1
In the Model Builder window, expand the Results>Velocity (spf)>Streamline 1 node.
View 3D 2
1 Right-click Results>Views and choose View 3D.
2 Use the Graphics toolbox to get a satisfying view.
3 In the Settings window for View 3D, locate the View section.
4 Select the Lock camera check box.
Next, apply the view to the velocity plot.
Velocity (spf)
1 In the Model Builder window, under Results click Velocity (spf).
2 In the Settings window for 3D Plot Group, locate the Plot Settings section.
3 From the View list, choose View 3D 2.
4 On the Velocity (spf) toolbar, click Plot.
Stress (solid)
The last plot shows the von Mises stress and deformation distribution in the container. To
reproduce the Figure 5, apply the View 3D 2.
Velocity (spf)
1 In the Settings window for 3D Plot Group, locate the Data section.
2 From the Data set list, choose Study 1/Solution 1 (sol1).
3 On the Velocity (spf) toolbar, click Plot.